Modular pipe formation apparatus

ABSTRACT

A modular plastic pipe formation apparatus, wherein at least two components of the pipe formation apparatus are disposed with respect to at least one or more respective modules.

TECHNICAL FIELD

A plastic pipe formation apparatus is disclosed. Also disclosed is amethod of relocating and assembling a pipe formation apparatus, and asystem for the production of plastic pipe. The apparatus can bemodularised and transported, and finds particular application for use inmanufacturing plastic pipe on site, or in close proximity of the pipelaying site. However, it is to be appreciated that the apparatus hasbroader application, and is not limited to such use.

BACKGROUND ART

Plastic pipe has a variety of industrial uses, including water supply,sewerage and waste water, transportation of gas and liquids, as well asa protective barrier for electrical and telecommunication cables.Plastic pipes are particularly useful as they are corrosion resistantflexible and offer weight advantages compared to alternative pipeconstruction materials such as copper, cast-iron and other metals. Thesequalities provide significant cost savings, and plastic pipes have beenutilised extensively in the water, agriculture, mining, construction,infrastructure, energy, electrical and telecommunication sectors.

Plastic pipes are manufactured by pipe extrusion inside a factory,thereby allowing production in a controlled environment. Plastic pipeextrusion generally involves feeding raw plastic material through ahopper into the barrel of the extruder. Inside the barrel, a rotatingscrew rotates and advances the plastic feed, with the assistance ofheaters, to melt and pressurise the plastic feed into molten plastic.The pressurised molten plastic is then forced through a die having anannular profile, thereby producing an extruded pipe. The newly extrudedpipe is then passed through a series of cooling tanks, that spray waterto solidify the plastic pipe. The pipes may then be coiled for storageand/or transportation before pipe laying.

With larger diameter pipes, there can be substantial difficulty incoiling the pipe to a coil which can be transported for long distances.For example, the pipe may be manufactured from a factory in anindustrial area which needs to be transported by conventional means suchas by ship, road and rail. These modes of transport have physicallimitations on size and bulk of cargo, therefore large diameter pipesare usually manufactured in sections of manageable size and weight,typically with a length of 20 metres. These sections are transported tothe site for pipe laying, where multiple sections are joined together bya coupling, which may involve plastic welding of the ends of the pipesections. Such coupling of the pipe sections is time consuming and addsadditional costs to labour and materials.

SUMMARY OF THE DISCLOSURE

In a first aspect, a modular plastic pipe formation apparatus isdisclosed, wherein at least two components of the pipe formationapparatus are disposed with respect to at least one or more respectivemodules.

By modularising at least part of the pipe formation apparatus, pipemanufacture can take place on site (at least for bulky, space-consumingstages). This can save on transportation and cost, as outlined in detailhereafter.

In one form, one of the components is a plastic extruder. The modulecontaining the plastic extruder may further comprise a plastic rawmaterial dryer and a die head.

In one form, the module for the plastic extruder further comprises apipe corrugator to corrugate extruded pipe from the die head.

In an alternative form, the plastic pipe formation apparatus furthercomprises a corrugator module for positioning adjacent to the plasticextruder module to receive therefrom and corrugate extruded pipe. Aseparate corrugator module allows the operator to selectively configurethe machine to produce straight wall or corrugated pipe, by simplyinserting or removing the corrugator module from the plastic pipeformation apparatus.

In one form of the modular plastic pipe formation apparatus, at leastanother one of the components comprises a cooling tank. In a furtherform, two or more cooling tank modules are provided in series to receiveextruded plastic pipes therein for cooling. The cooling tank cools thehot extruded plastic pipe to a solid state. Typically, the cooling tankcontains a water spray for cooling the plastic.

In yet a further form, a first of the two or more cooling modulescomprises a vacuum water tank. The vacuum assists extruding the moltenplastic pipe from the die head.

In a further form, the modular plastic pipe formation apparatus furthercomprises one or more modules comprising one or more of the followingcomponents: a haul off caterpillar, a cutter, a pipe sliding table, atipping table, and a coiler.

In one form, the plurality of modules are aligned in a predeterminedmanner during formation of plastic pipe.

In another form, a module or each module of the plastic pipe formationapparatus is adapted to be transportable.

In one form of the modular plastic pipe formation apparatus, theplurality of modules are adapted to be coupled to each other in use, anddecoupled, from each other during transportation of the apparatus.

In one form of the modular plastic pipe formation apparatus at least oneof the modules comprises a standardised shipping container, optionallymodified for use in the apparatus.

In an alternative form, at least one of the modules comprises acontainer or supporting framework for use in the apparatus and having atleast some of the features of a standardised shipping container tofacilitate its transportation. By providing modules having features ofstandard shipping containers, it allows the modules to be handled andtransported using existing vehicles and infrastructure. This keeps thecosts of transporting the apparatus to a minimum.

In one form of the modular plastic pipe formation apparatus, theadjacent modules are adapted for being locked together during pipeformation. Locking the modules together ensures the modules are in theirdesired predetermined arrangement. Thus, the operator can be confidentthe modules are correctly arranged, and will not deviate in position.

In one form, the modular plastic pipe formation apparatus furthercomprises an adjustment mechanism for closely positioning adjacentmodules prior to locking them together. This mechanism may take the formof a winch, with a winch base attached to one module, and the end of awinch cable attached to another module, the operation of the winchdrawing the modules together. This allows the modules to be initiallypositioned in a roughly arranged arrangement by a crane. Subsequently,the adjustment mechanism allows the modules to be closely positioned andaligned to each other. This avoids using cranes to position modules inprecise locations, which can be difficult given the modules may be thesize of shipping containers, which are bulky and awkward to lift andposition.

In one form, the modular plastic pipe formation apparatus furthercomprises external supports for supporting respective modules. Theexternal supports can comprise adjustable jacks to adjust the positionor angle of the supported module. In another form, the external supportsfurther comprise piles for securing into underlying ground. The externalsupports allow the modules to be placed and used on uneven or softerground, as well as providing ground clearance for water drainage.

In one form, the position or angle of a component at one module isadjustable with respect to its module. In a further form, the pluralityof components disposed within the modules are adjustable in position orangle, enabling the plurality of components to be aligned for pipeformation. This allows the components of pipe forming apparatus to bealigned even if the supporting modules are not perfectly aligned. Thismay be advantageous where the production site is not perfectly level, orif the modules have not been precisely arranged.

In one form, the apparatus further comprises a reference laser beam toaid in alignment of the components and/or the modules.

In a second aspect, a pipe formation system is disclosed comprising:

-   -   a plurality of modules with each module comprising at least one        component of the pipe formation system; and    -   an alignment mechanism for aligning a component in one module        with a component in another module.

In one form of the system, the modules are configurable as transportablecontainers, the manufacturing system further comprising a transporterfor conveying the modules to and from a pipe production site, with thetransportable containers and transporter together providing a mobilepipe manufacturing system. The transporter may be in the form of asemi-trailer, rail car or a container ship.

In one form, at least one component of the system is a plastic extrader.

In one form, the pipe formation system further comprises a coileroptionally disposed with respect to a module.

In one form, the pipe formation system further comprises pipe trailersfor transporting pipe to the pipe laying site.

In one form, the pipe formation system further comprises a powergeneration unit optionally disposed with respect to a module.

In one form, the pipe formation system further comprises a chilling unitfor providing a closed circuit cooling water supply to a cooling tankcomponent, the chilling unit and/or the cooling tank each optionallydisposed with respect to a module.

With the power generation unit and the chilling unit as a modular andtransportable part of the pipe formation system, the pipe formationsystem can be self sufficient, without reliance on existinginfrastructure such as a power grid and plumbing at the production site.This allows the system to be employed at a production site in a remotelocation.

In one form, hot air may be extracted from inside the freshly extrudedpipe, or from other locations in the pipe formation system or apparatus.This hot air can be recycled to the raw material dryer for use in dryingthe raw material. This can reduce the energy requirements of the system.

In another aspect, a method for forming plastic pipe employing a form ofthe apparatus of the first aspect is disclosed. The method comprises:

-   -   arranging two or more respective modules with respect to each        other; and    -   arranging two or more respective components of the pipe        formation apparatus with respect to each other.

In a further form, the method further comprises forming plastic pipe.

In another aspect, a method of forming plastic pipe is disclosed, usinga modular plastic pipe formation apparatus that comprises a plurality ofmodules supporting components of the pipe formation apparatus, themethod comprising:

-   -   arranging the plurality of modules in a predetermined manner at        a production site;    -   arranging two or more respective components of the pipe        formation apparatus; and    -   supplying the plastic pipe formation apparatus with plastic raw        material.

In one form, the method further comprises coupling the modules together.In a further form, the coupling of the modules and arranging of thecomponents comprises:

-   -   locking the modules together; and    -   aligning the components of the plastic formation apparatus to        enable pipe formation.

In one form of the method, the components are aligned using a laser fordetermining the position of the components and then, as necessary,adjusting alignment of the components.

In another aspect, a method of establishing a mobile plastic pipemanufacturing site is disclosed. The site that is adapted to locate amodular plastic pipe formation apparatus that comprises a plurality ofmodules supporting components of the pipe formation apparatus. Themethod comprises:

-   -   transporting the modules to the site;    -   arranging the modules in a predetermined manner at the site;    -   coupling the modules together;    -   supplying raw materials, power and water to the plastic pipe        formation apparatus; and    -   forming plastic pipe.

In one form of the method, the coupling of the modules togethercomprises locking the modules together; and aligning the components ofthe plastic formation apparatus to enable pipe formation.

In one form of the method, the modules and the components are initiallyconfigured in a transportable state, with the method further comprisingconfiguring the components and modules to a production state after thestep of transporting the modules to the production site.

In one form of the method, after plastic pipe manufacturing at theproduction site has ceased, the modular plastic pipe formation apparatusmay be relocated and set up at a second production site, with the methodthen comprising:

-   -   decoupling the modules;    -   configuring the components and modules to a transportable state;    -   transporting the modules from the production site to the second        production site;    -   positioning the modules in a predetermined manner;    -   coupling the modules together;    -   supplying raw materials, power and water to the plastic pipe        formation apparatus; and    -   manufacturing plastic pipe.

The apparatus, system and methods disclosed herein allow production ofpipe at remote locations, whereby pipe formation may be performed atclose proximity to where the pipe will be used. This reducestransportation of the finished product, which can be considerablyexpensive to transport for long distances. Thus actual transportationcosts are reduced as the finished product may not even need to travel atall from the point of manufacture to the site. This also considerablyreduces the timeline from when the pipe is manufactured to when it isdelivered, therefore the installation time is also reduced.

Furthermore, as the manufactured pipe only needs to move a relativelyshort distance between manufacturing and pipe laying, the length of pipeproduced can be increased. Transportation of large sections may beachieved by utilising specialised pipe trailers to move the pipes fromthe production location to the pipe laying location. Manufacturing caneven take place adjacent to where pipe is to be laid.

By producing longer lengths of pipe the number of welds and couplingsbetween pipe sections can be reduced, leading to less material, labourand overall costs for the pipeline. In addition, fewer welds andcouplings lead to less chance of defects in the couplings and lesschance of compromising the integrity of the pipeline.

In addition, longer pipe sections and shorter transport distancesreduces overall handling of the pipe, and reduces possibility of freightdamage of the pipe in transit. In addition, shorter transport distancesimproves public safety as bulky pipes do not need to travel longdistances on public roads.

A mobile pipe manufacturing facility also allows the supply of pipe thatmay otherwise be logistically difficult to deliver. For factory-producedpipes, there has been a reliance on transportation capable oftransporting manufactured pipe between the factory and pipe site. Inremote locations, traditional transportation methods may not have thecapacity to transport bulky pipe through rugged or remote terrain. Byproviding a mobile pipe manufacturing facility, the pipe extrusionmachine itself may be separated into manageable, containerised modules.These modules may then be more easily transported to a remote location,and set up to manufacture pipe on location.

Furthermore, in this system, by providing the pipeline customer withmeans to produce pipe at close proximity to the site, it allowsadditional flexibility for the customer to easily and rapidly changepipe specifications, and to increase or decrease production of pipe.This flexibility improves delivery time and simplifies storage andhandling costs on site.

BRIEF DESCRIPTION OF THE DRAWINGS

Notwithstanding any other forms which may fail within the scope of theapparatus, system and method as set forth in the summary, specificembodiments will now be described in which:

FIG. 1 is a plan view of a modular plastic pipe formation apparatusaccording to a first embodiment;

FIG. 2 is a side view of the modular plastic pipe formation apparatus ofFIG. 1;

FIG. 3 is a plan view of a modular plastic pipe formation apparatusaccording to a second embodiment;

FIG. 4 is a side view of the modular plastic pipe formation apparatus ofFIG. 3;

FIG. 5 is a plan view of the modules of the plastic pipe formationapparatus of FIG. 3;

FIG. 6 is a side view of the modules of the plastic pipe formationapparatus of FIG. 3;

FIG. 7 is an end view of a module of the plastic pipe formationapparatus of FIG. 3 with the end doors mounted for transportation;

FIG. 8 is a sectioned view of a module of the plastic pipe formationapparatus along section B-B in FIG. 6;

FIG. 9 is a sectioned view of a module of the plastic pipe formationapparatus along section C-C in FIG. 6;

FIG. 10 illustrate the top, side and sectioned end view of a firstmodule of FIG. 5;

FIG. 11 illustrate the top, side and sectioned end view of a secondmodule of FIG. 5;

FIG. 12 illustrate the top, side and sectioned end view of a thirdmodule of FIG. 6;

FIG. 13 illustrate the top, side and sectioned end view of a fourthmodule of FIG. 6;

FIG. 14 illustrate the top, side and sectioned end view of a fifthmodule of FIG. 6;

FIG. 15 illustrate the top, side and sectioned end view of a sixthmodule of FIG. 6;

FIG. 16 illustrate the top, side and sectioned end view of a seventhmodule of FIG. 7;

FIG. 17 illustrate the top and side view of an external support for themodules; and

FIG. 18 illustrate the top and side view of an internal support frame.

DETAILED DESCRIPTION

FIG. 1 illustrates a plan view of a modular plastic pipe formationapparatus 1 configured for smooth wall pipe production. The pipeformation apparatus 1 comprises a series of modules 3, each comprisingmodified shipping containers, within which are disposed components ofthe pipe formation apparatus. The modules 3 are coupled to each other ina predetermined layout, allowing the components therein to be alignedfor pipe production.

In the first module 5, there is provided a raw material dryer 7, screwextruder 9 and a die head 11. In the second module 15, there is provideda vacuum water tank 17. The third and fourth modules 19 house watercooling tanks 21. The fifth module 23 houses a haul off caterpillar, andthe sixth module 27 houses a cutter 29.

Other components for pipe production may include, a raw material feedingand storage component 31, a power generation unit 33, a chilling unit35, pipe sliding table/tipping table 37 and a pipe coiler 39.

In pipe production, power and water is supplied to the first module 5from the power generation unit 33 and chilling unit 35. Raw plasticmaterial is fed from the raw material feeding and storage component 31to the raw material dryer 7, where the raw plastic material is driedbefore feeding into the hopper of the screw extruder 9. The raw plasticmaterial is then heated and pressurised in the barrel of the screwextruder 9, thereby creating a polymer resin in a molten state. Themolten polymer is then forced through the die head 11, thereby creatinga pipe extrusion. The hot pipe extrusion enters and is drawn into vacuumwater tank 17, where the vacuum assists in pulling the extrusion fromthe die head. A series of water spray nozzles within the vacuum watertank 17 sprays water to cool the newly extruded pipe, to aid insolidification.

To assist in passing the extruded plastic pipe through the pipeformation apparatus 1, the haul off caterpillar 25 pulls the solidifiedpipe from the water cooling tanks 21 and passes the pipe through thecutter 29. The cutter 29 cuts the pipe at intervals as selected by theoperator, to provide pipe of desired length.

The finished pipe is then transferred to a pipe sliding table/tippingtable 37 where the pipe is prepared for storage and/or transportation.For flexible pipes, this may include coiling the pipe on the coiler 39as illustrated in FIGS. 1 and 2. For larger diameter pipes that cannotbe coiled, the pipe may be lifted directly from the pipe slidingtable/tipping table 37 to a storage area or a pipe transporter.

The components of the modules 3 will now be described in further detail.

The raw material feeding and storage component 31 comprises portablesilos 41, e.g. of 10 to 50 tonne capacity. As illustrated in FIG. 2, thesilo 41 may be tilted such that the raw material flows to the rear ofthe silo 41 to assist in extraction of the raw material. The rawmaterial is extracted from the silo by pipe work or flexible hose with asuction unit, thereby sucking the raw material from the silo, andsupplying it to bulker bags 43 for temporary storage before feeding tothe raw material dryer 7.

The raw material dryer 7 dries the plastic raw material before feedinginto the extruder 9. The raw material dryer may utilise power and heatfrom the power generation unit 33. Additionally as alternatively, hotair may be extracted from inside the freshly extruded pipe, and recycledto the raw material dryer 7 for drying of the plastic raw material. Thiscan conserve energy by reducing or eliminating additional energyrequirements for drying the raw material.

The extruder 9 may be a single or double screw extruder. This may be acommercial off-the-shelf unit, or a modified unit with reduced totaloutput power to match the power generation unit 33. A suitable extrudermay include extruders manufactured by BATTENFELD-CININNATI GmbH. Locatedwith the die head 11, is a pipe head. The pipe head may have the abilityto produce single, double or triple layer pipe. Various pipe sizes maybe produced, including 400 mm, 630 mm, 1200 mm and 1600 mm diameterpipe.

Extruder line colourer 12, applies coloured lines to the extruded pipefor pipe marking and identification purposes. Although only one extruderline colourer 12 is illustrated, in other embodiments, more than oneextruder line colourer 12 may be used. As illustrated in FIG. 1, theextruder line colourer 12 when configured for use, projects from thefirst module 5. Thus, an additional container 13 may be arrangedadjacent to first module 5 to provide overhead protection to theextruder line colourer 12. Furthermore, container 13 may provide aworking shelter for operators of the apparatus 1 whilst allowing themaccess to components of the apparatus 1.

The vacuum water tank 17 comprises a cylindrical tank in which therecently extruded pipe passes through. Inside the tank is a series ofwater sprays to cool the hot extruded plastic pipe. The ends of thecylindrical tank are provided with a rubber boot or flaps. The rubberboot or flaps permit the extruded pipe to enter the tank and at the sametime forms an atmospheric seal between the inside of the tank and thesurrounding atmosphere. Vacuum pumps are disposed below the cylindricaltank to provide a vacuum inside the cylindrical tank. Water and power tothe tank is provided by a respective water and electrical circuit, whichwill be described further below.

The cooling water tanks 21, comprise a cylindrical tank provided withwater sprays similar to the vacuum water tank 17. It would beappreciated that it is possible to use multiple vacuum water tanks 17 inplace of the cooling water tanks 21.

The haul off caterpillar 25, comprises powered caterpillar tracks thatgrip the outer surface of the finished pipe to pull the pipe from thecooling tanks 21.

The cutter 29 and coiler 39 may be commercial off-the-shelf units.Ideally, the coiler 39 coils pipe with low ovality or deformation, suchas the Low Ovality Technology coilers manufactured by PIPE COILTECHNOLOGY LIMITED, UK.

The pipe sliding table 37 is adapted to receive and support cut pipefrom the cutter 29, and may comprise rollers to assist in sliding.Alternatively, or in conjunction, a tipping table may be used toreceive, and transfer sections of cut pipe to a pipe trolley, or othercomponent.

The power generation unit 33, comprises either a diesel, petrol or gasgenerator disposed at a 20 or 40 foot shipping container. The containermay further include a fuel tank for the generator. The module containingthe power generation unit 33 may be adapted for outdoor or indoor usewhere it may be fitted with breather and exhaust piping.

Power from the power generation unit 33 is provided to the first module5, where it is distributed to subsequent modules 3 of the apparatus 1.Each module 3, will have electrical power connectors to receiver powerfrom a module, as well as distributing power to another connectedmodule. That is, the first module 5 will be electrically connected tothe second module 15, which in turn is electrically connected to thethird module 19, etc. Advantageously, this reduces the need to connecteach individual module 3 with an electrical power line from the powergeneration unit 33, and simplifies assembly of the pipe formationapparatus 1 at the production site. An exception is power supply to thechilling unit 35, where it may be advantageous to directly connect powerfrom the power generation unit 33.

Alternatively, for production sites where electrical mains power isavailable, the apparatus 1 may receive electrical power from the mainssource. Similar to the above mentioned embodiment, electrical mainspower can be provided to the first module 5, where it will bedistributed to subsequent modules 3.

The water chilling unit 35 may comprise an absorption refrigerator or acompressor refrigerator inside a 20 or 40 foot shipping container. Thecontainer may further include a water tank, and the water chilling unitmay be adapted for outdoor or indoor use.

Optionally, the water chilling unit may be connected to, or co-locatedwith, the power generation unit 35.

The water chilling unit 35 is piped to the first module 5, and coolswater for a closed circuit water supply for the apparatus 1. The watercircuit comprises a cool water line and a hot water line runningparallel to modules 5, 15 and 19. The modules 5, 15 and 19 have heightadjustable hot and cold pipes disposed therein, and the pipes arecoupled to each other to form part of the closed water circuit. Theclosed water circuit provides water to the water cooling tanks 21,vacuum water tank 17, and components in module 5.

Alternatively, for production sites with an existing water circuit, theapparatus 1 may exchange cool and hot water with the existing watercircuit. Similar to the water circuit described in the embodiment above,the water circuit can be connected to the first module 5, where it willbe coupled to the pipes of subsequent modules 3.

Optionally, a corrugator, either disposed in the first module 5, or in aseparate module, may be positioned between the die head 11 and thevacuum water tank 17. The corrugator may be a commercial off-the-shelfsystem, such as the DROSSBACH HD series manufactured by DROSSBACH GmbH,or ITIB corrugator series manufactured by ITIB MACHINERY INTERNATIONALS.p.A. The corrugator, in use, moves back and forth axially to theextruded pipe. In an embodiment, part of the corrugator may envelopepart of the die head 11. In a further embodiment, part of the corrugatormay protrude from a corrugator module and into the first module 5.Alternatively, the die head 11 may extend from the first module 5, andprotrude into the corrugator module.

Generally, each module 3 is provided with a lock 45 to allow adjacentmodules 3 to be locked to one another. This ensures the modules arecorrectly arranged with respect to each other during pipe formation.Furthermore, an adjustment mechanism such as a winch may be used forpulling modules together. Thus, modules can be placed in close proximityto each other, and the winch may then pull modules together before thelocks 45 are engaged.

The components within each module 3 are also adjustable in position orangle with respect to the module they are disposed in. In one form, thecomponents are supported by adjustable jacks on top of the module floor.Adjustment may either be mechanical, hydraulic, electro-mechanical or,by other suitable actuation means. Furthermore, actuation may beautomated or semi-automated, and controlled by a computer. Theadjustability of components within each module allows alignment of thecomponents when the modules themselves are not perfectly aligned.

A referencing laser may be used to determine the relative positions ofthe modules 3 or components, and provide information to allowcorrections to the position of the modules 3 or components therein. Thelaser may be set up at either or both ends of the apparatus 1, with thelaser directed co-axially to the pipe extrusion axis.

In one embodiment, witness panes in the path of the laser beam may beattached to the components and/or modules. The location of the laserreflection on the panes will thus provide information on the position ofthe components and/or modules relative to the reference laser. It shouldbe appreciated that other methods of alignment may be used (e.g. sightgauges).

The modules 3 are generally modified 20 foot or 40 foot shippingcontainers. In one form, the sides or top of the modules may have doorsto allow ventilation during pipe formation. In another form, the modulesmay be an open frame, and the top and/or sides may simply be left openduring transportation, or covered with a tarpaulin.

A second embodiment of the modular plastic pipe formation apparatus 101is illustrated in FIGS. 3 to 16. Features corresponding to thosepresented previously discussed are similarly numbered with “100”preceding the similar feature.

In the apparatus 101 of the second embodiment, the raw material dryer107 is contained in a separate first module 105. The second module 106,contains the screw extruder 109 and the die head. The third module 115,fourth module 119 and fifth module 120 contain vacuum water tanks 117and/or water cooling tanks 121. The sixth module 123 contains a watercooling tank 121 and a haul off caterpillar 125. The seventh module 127contains a cutter 129 and a second haul off caterpillar 126. A secondhaul off caterpillar assists in pulling longer pipes.

The modules 103 of the apparatus 101 generally comprise modified 20 footand 40 foot containers. The modules 103 are supported by externalsupports 151, comprising adjustable jacks 153 supported by screw piles155 driven into the ground.

The external support 151 is shown in more detail in FIG. 17. The screwpile 155 is selected from a type, size and length suitable to supportthe weight of the modules 103 for the underlying ground. The adjustablejack 153 comprises of a top plate 157, bottom plate 153 and adjustmentbolts 161. The adjustment bolts 161 allow adjustment of the height ofthe supported modules 103. The top plate 157 is sufficient span tosupport two adjoining modules at their respective ends as illustrated inFIG. 6. However, it is to be appreciated that additional externalsupports 151 may be used at locations along the intermediate length ofthe modules 103 as required. Furthermore the span of the top plate 157also enables a degree of lateral displacement to enable adjacent modules103 to be aligned.

Advantageously, the external supports 151 elevate the modules 103 abovethe underlying ground which assists in drainage if the apparatus 101 islocated outdoors. Furthermore, the use of piles reduce the need for aflat hard surface to support the modules. Thus, less preparation isrequired at the pipe manufacturing site. In addition, the apparatus maybe set up in areas with poor ground soil quality (e.g. softer, sandy,loamy, uncompacted, etc soil or ground).

An internal support frame 163 for supporting components within a module103 is best illustrated in FIG. 18. The support frame 163 comprises aframe body 165 and adjustable locking mounts 168. The adjustable lockingmounts 168 are mountable to the floor reinforcements 167 on the floor ofthe modules 103. The adjustable locking mounts 168 enable the frame tobe linearly and angularly displaced as required to ensure the componentsin the modules 103 are aligned.

The modules 103 will now be described with reference to FIGS. 5 to 16.As illustrated in FIG. 7, the modules are reduced to standard shippingcontainer sizes during transportation. This may include attachingremovable container doors 171. The doors 171 are typically removedbefore assembly of the apparatus 101.

FIG. 8 illustrates a sectioned view of module 106, as an example of anopen in-use configuration of a module 103. The module 106 has a folddown side wall 173, which folds down to rest on an external support 151.The fold down side wall 173 can then function as a floor for techniciansto access the apparatus 101.

The module 106 is also provided with an open top section 175. Thisallows components of the apparatus 101 to extend above the top sectionof the module 106 when configured for use. This also advantageouslyimproves ventilation within the module. To ensure the apparatus isprotected from weather, including rainwater and dust, a surroundingcanvas awning 177 is provided above and around the open top section 175,extending to the fold down side wall 173. This ensures the techniciansas well as the components are protected from external elements. FIG. 9illustrates an alternative awning 178, where the awning extendsoutwardly from the top of the module 127.

Between the ends of each module 103 there is provided a rubberconcertina-like boot. This ensures a weather, water and dust proof sealbetween adjoining modules 103. The boot may be attached to each end ofthe module 103 by bolts.

On the modules 103 has enclosed tops. The tops may be angled toward thelongitudinal centre of the module, and to one side. This ensuresdrainage of rainfall is directed away from the boot sealing the ends ofthe adjacent modules 103, thus reducing the chance of water leaking intothe modules 103.

The modules 103 are provided with ventilation louvers 179 to assist inventilation of the apparatus 101. Furthermore, air-conditioning units181 may be provided to regulate the temperature within the apparatus101.

Between modules 106 and 115, the vertical beams 183 and 185 at theadjoining ends may be removable. This facilitates access to the die headwhich is located in the region of the adjoining ends. To maintainstructural integrity of the modules 106 and 115, an additional verticalbeam may be located at an alternative location.

To establish a mobile plastic pipe formation site, a suitable site isfirst located. The site may be outdoors in the open, under coveredshelter, or indoors. Generally, a flat ground, at least the size of theapparatus is required. The ground can be a hard surface, such as bitumenor concrete. Alternatively, a screw pile and adjustable jacks may beused to support the modules. This latter approach is especially suitablefor softer ground. The modules, in the form of transportable containersare delivered to the site. Since the containers have features ofstandard 20 or 40 foot containers, existing transportation and handlingequipment can be used.

Once the modules 3 are transported to the production site, the modulesmay be configured from their transportation state to a pipe productionstate. This may include opening and/or removing the container doors 171,and removing any packing or protective equipment required duringtransportation.

The modules 3 are then arranged as required in the predetermined mannerat the production site. The modules 3 are then drawn into closeproximity with each other using a winch, and then locked together.

Alternatively, two modules are first arranged in the predeterminedmanner (above) at the site. The two modules are then drawn to closeproximity using a winch, and then locked together. A further module isthen arranged as required in the predetermined manner.

The further module is then positioned in close proximity to the firsttwo modules that have been locked. The further module is then drawntowards the first two modules with a winch, and then locked. This can berepeated until all modules required have been arranged and locked asrequired.

When all the modules have been arranged and locked, the componentssupported by the modules may then be adjusted in position and aligned toeach other. As described above, this may be done manually orautonomously, and may be aided with a reference laser.

The electrical connectors and the coupling for the water pipes betweeneach module 3 are then connected, to provide power and water for themodules. Once this is completed, and water, power and raw plasticmaterials are supplied to the apparatus 1, the plastic pipe formationsite is established and pipe formation operations can commence.

When plastic pipe formation at the site is complete, the pipe formationapparatus can be moved to a new site. This involves decoupling theelectrical connectors, water pipes and modules. The modules are thenconfigured to a transportable state, such as attaching and/or closingdoors, adding packing or protective equipment, and adjusting position ofcomponents so they fit within the shipping container dimensions. Themodules may then be transported to the new production site, and themethod of establishing a plastic pipe formation site described above isrepeated.

In projects where a long continuous pipeline is required, the plasticpipe formation apparatus may be intermittently moved along the proposedpipeline as the pipe is laid. That is, a first mobile pipe manufacturingsite is located near the start of the pipeline, and pipe is formed,transported and the pipe laid. As the front of the pipe laying siteadvances forward, the formed pipe needs to be transported further fromthe pipe manufacturing site to the pipe laying site. Thus, the time andcost of transportation of pipe increase. It may then be economical torelocate the pipe formation apparatus 1 to another site closer to theadvancing pipe laying site, or even ahead of it. Alternatively, a secondpipe formation apparatus can be located at the new site, with the firstapparatus being readied for a third site, etc. Thus the apparatusprovides a mobile pipe manufacturing site which advantageously allowspipe production to keep up with the pipe laying site.

In the claims which follow and in the preceding description, exceptwhere the context requires otherwise due to express language ornecessary implication, the word “comprise” or variations such as“comprises” or “comprising” is used in an inclusive sense, i.e. tospecify the presence of the stated features but not to preclude thepresence or addition of further features in various embodiments of theapparatus, system and method.

It is to be understood that, if any prior art publication is referred toherein, such reference does not constitute an admission that thepublication forms a part of the common general knowledge in the art, inAustralia or any other country.

1.-36. (canceled)
 37. A modular plastic pipe formation apparatuscomprising a plurality of modules wherein each module comprises at leastone component of the pipe formation apparatus located therein, whereinthe plurality of modules are aligned in a predetermined manner duringformation of plastic pipe.
 38. The modular plastic pipe formationapparatus of claim 37, wherein one of the modules comprises a plasticextruder and the apparatus further comprises one or more modulescomprising one or more of the following components: a plastic rawmaterial dryer; a die head; a pipe corrugator; a corrugator module; acooling tank; a haul off caterpillar; a cutter; a pipe sliding table; atipping table; and a coiler.
 38. The modular plastic pipe formationapparatus of claim 37, wherein at least one of the plurality of modulesis adapted to be transportable.
 39. The modular plastic pipe formationapparatus of claim 37, wherein the plurality of modules are adapted tobe coupled to each other in use and decoupled from each other duringtransportation of the apparatus.
 40. The modular plastic pipe formationapparatus of claim 37, wherein at least one of the plurality of modulescomprises: a standardised shipping container optionally modified for usein the apparatus; or a container or supporting framework for use in theapparatus and having at least some of the features of a standardisedshipping container to facilitate its transportation.
 41. The modularplastic pipe formation apparatus of claim 37, wherein the adjacentmodules are adapted for being locked together during pipe formation. 42.The modular plastic pipe formation apparatus according to claim 41,further comprising an adjustment mechanism for closely positioningadjacent modules prior to locking them together.
 43. The modular plasticpipe formation apparatus of claim 37, further comprising externalsupports for supporting respective modules, wherein the externalsupports comprise adjustable jacks to adjust the position or angle ofthe supported module.
 44. The modular plastic pipe formation apparatusof claim 37, wherein the plurality of components disposed within themodules are adjustable in position or angle, enabling the plurality ofcomponents to be aligned for pipe formation.
 45. The modular plasticpipe formation apparatus according to claim 44, further comprising areference laser beam to aid in alignment of the components and/or themodules.
 46. A pipe formation system comprising: a plurality of modules,with each module comprising at least one component of the pipe formationsystem; and an alignment mechanism for aligning a component in onemodule with a component in another module.
 47. The pipe formation systemof claim 46, wherein the modules are configurable as transportablecontainers, the pipe fotmation system further comprising a transporterfor conveying the modules to and from a pipe production site, with thetransportable containers and transporter together providing a mobilepipe formation system.
 48. A method of forming plastic pipe, using amodular plastic pipe formation apparatus that comprises a plurality ofmodules supporting components of the pipe formation apparatus, themethod comprising: arranging the plurality of modules in a predeterminedmanner at a production site; arranging two or more respective componentsof the pipe formation apparatus; supplying the plastic pipe formationapparatus with plastic raw materials; coupling the modules together; andaligning the components of the plastic formation apparatus to enablepipe formation.
 49. The method of claim 48, wherein the coupling of themodules and arranging of the components comprises locking the modulestogether.
 50. The method of claim 48, wherein the components are alignedusing a laser for determining the position of the components and then,as necessary, adjusting alignment of the components.